Electronic subassembly for a personal care product

ABSTRACT

An electronic subassembly for a personal care product with a housing defining a chamber having an open end. A first circuit board having a rigid end is positioned within the chamber and a flexible portion is positioned outside the chamber. A second circuit board is positioned within the chamber. The second circuit board has a connector dimensioned to receive the rigid end of the first circuit board.

FIELD OF THE INVENTION

The present invention relates to electronic personal care products andmore particularly to heated razors for wet shaving.

BACKGROUND OF THE INVENTION

Personal care products are becoming more advanced and thus often requirethe incorporation of electronic components to deliver new and/orimproved consumer benefits. Electronic components are subject to failurewhen exposed to a wet environment, such as the bathroom. Furthermore,electronic components must be small to fit within a personal careproduct, such as a razor or a toothbrush. Accordingly, electricalcomponents and fittings are typically very delicate and can breakeasily. In order to provide a safe and functional personal care product,the electrical components must be assembled and sealed against wateringress in a reliable cost-effective manner.

Accordingly, there is a need to efficiently assemble and seal theelectronic components of a personal care product in a simple andreliable manner.

SUMMARY OF THE INVENTION

The invention features, in general, a simple, efficient method ofassembling an electronic subassembly for a personal care product bymanufacturing a hollow housing defining a chamber having a first openend and an opposing second open end. A rigid end of a first circuitboard is inserted into the first open end of the housing. A secondcircuit board subassembly having a second circuit board is inserted intothe chamber through the second open end. The first circuit board isconnected to the second circuit board within the chamber of the housing.

The invention also features, in general, a simple, efficient electronicsubassembly for a personal care product with a housing defining achamber having an open end. A first circuit board having a rigid end ispositioned within the chamber and a flexible portion is positionedoutside the chamber. A second circuit board is positioned within thechamber. The second circuit board has a connector dimensioned to receivethe rigid end of the first circuit board.

The details of one or more embodiments of the invention are set forth inthe accompanying drawings and the description below. It is understoodthat certain embodiments may combine elements or components of theinvention, which are disclosed in general, but not expressly exemplifiedor claimed in combination, unless otherwise stated herein. Otherfeatures and advantages of the invention will be apparent from thedescription and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter that is regarded as thepresent invention, it is believed that the invention will be more fullyunderstood from the following description taken in conjunction with theaccompanying drawings.

FIG. 1 is a perspective view of one possible embodiment of a personalcare product.

FIG. 2A is an assembly view of an electronic subassembly, which may beincorporated into the personal care product of FIG. 1.

FIG. 2B is a side view of the electronic subassembly of FIG. 2A.

FIG. 2C is a cross section view of the electronic subassembly, takengenerally along the line 2C-2C of FIG. 2A.

FIG. 3 is an assembly view of a second electronic subassembly, which maybe incorporated into the personal care product of FIG. 1.

FIG. 4 is an assembly view of the electronic subassembly of FIG. 3 andthe electronic sub assembly of FIG. 2B.

FIG. 5 is a partial cross section view of the personal care product,taken generally along the line 5-5 of FIG. 1.

FIG. 6 is a partial cross section view of the personal care product,taken generally along the line 6-6 of FIG. 1.

FIG. 7 is a partial cross section view of the personal care product,taken generally along the line 7-7 of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, one possible embodiment of the present disclosureis shown illustrating a personal care product 10 having an electronicsubassembly 12. Although the personal care product 10 shown is a wetshaving razor system, it is understood that other personal care productsmay include, but are not limited to a foil type shaving razor, atoothbrush, a shaving brush, a powered cleansing apparatus, an epilator,and other powered personal products. These products may be used in a wetenvironment, such as the bathroom. In certain embodiments, the personalcare product 10 may include a cartridge 14 (e.g., a shaving razorcartridge) mounted to a housing 16. The housing 16 may act as a handlefor a consumer to hold the personal care product 10. The housing 16 maybe injection molded, machined, or extruded.

As will be described in further detail below, the electronic subassembly12 may comprises a first circuit board subassembly 18 and a secondcircuit board subassembly (not shown). The first circuit boardsubassembly 18 may include a first circuit board 22 having a flexibleportion 24 and the housing 16 (e.g., a portion of the housing 16). Atleast a portion of the first circuit board 22 may be positioned insidethe housing 16 and at least a portion of the first circuit board 22(e.g., the flexible portion 24) may be positioned outside the housing16. In certain embodiments, the first circuit board 22 may be securedwithin the housing 16 by a plug 26. As will be explained in greaterdetail below, the plug 26 may be part of the housing 16 and created aspart of an injection molding process when the first circuit board 22 isassembled to the housing 16. The second circuit board subassembly (notshown) may be completely contained within the housing 16. Variouselectrical components may be contained within the housing 16 as part ofthe second circuit board subassembly (not shown). For example, thehousing 16 may hold a power source, such as one or more batteries (notshown) that supply power from the second circuit board subassembly (notshown), to the first circuit board subassembly 18 and then to anelectrical component 28 located outside the housing 16. In certainembodiments, the electrical component 28 may be a heating elementlocated on a surface of the cartridge 14 or the housing 16 to deliverheat to the skin during shaving. However, the battery in addition to, oralternatively, may supply power to other electrical componentsincluding, but not limited to motors, cooling systems and/or lights.

The cartridge 14 may be permanently attached or removably mounted to thehousing 16, thus allowing the cartridge 14 to be replaced. The cartridge14 may have a guard 30, a cap 32, and one or more blades 34 mounted tothe cartridge 14 between the cap 32 and the guard 30. The guard 30 maybe toward a front portion of the cartridge 14 and the cap 30 may betoward a rear portion of the cartridge 14 (i.e., the guard 30 is infront of the blades 34 and the cap 32 is behind the blades 34). Theguard 30 and the cap 32 may define a shaving plane that is tangent tothe guard 30 and the cap 32. The guard 30 may be a solid or segmentedbar that extends generally parallel to the blades 34.

In certain embodiments, the guard 30 may comprise a skin-engaging member36 (e.g., a plurality of fins) in front of the blades 34 for stretchingthe skin during a shaving stroke. The skin-engaging member 36 may beinsert injection molded or co-injection molded to the cartridge 14.However, other known assembly methods may also be used such asadhesives, ultrasonic welding, or mechanical fasteners. The skinengaging member 36 may be molded from a softer material (i.e., lowerdurometer hardness) than the cartridge 14. For example, the skinengaging member 36 may have a Shore A hardness of about 20, 30, or 40 toabout 50, 60, or 70. A softer material may enhance skin stretching, aswell as provide a more pleasant tactile feel against the skin of theuser during shaving. A softer material may also aid in masking the lesspleasant feel of the harder material of the cartridge 14 against theskin of the user during shaving.

In certain embodiments, the blades 34 may be mounted to the cartridge 14and secured by one or more clips 38 a and 38 b. Other assembly methodsknown to those skilled in the art may also be used to secure and/ormount the blades 34 to the cartridge 14 including, but not limited to,wire wrapping, cold forming, hot staking, insert molding, ultrasonicwelding, and adhesives. The clips 38 a and 38 b may comprise a metal,such as aluminum for acting as a sacrificial anode to help preventcorrosion of the blades 34. Although five blades 34 are shown, thecartridge 14 may have more or fewer blades depending on the desiredperformance and cost of the cartridge 14.

In certain embodiments, it may be desirable to provide heat in front ofthe blades 34. For example, the heating element 28 may be positioned infront of the guard 30 and/or the skin engaging member 36. The heatingelement 28 may comprise a skin contacting surface (e.g., a face plate)that delivers heat to a consumer's skin during a shaving stroke for animproved shaving experience. However, it is understood the heatingelement 28 may in addition to or alternatively supply heat to the blades34, either directly or indirectly. The heating element 28 may be mountedto either the cartridge 14 or to a portion of the housing 16.

FIGS. 2A, 2B, and 2C illustrate the first circuit board assembly 18.Referring to FIG. 2A, an assembly view of the first circuit boardsubassembly 18 is shown, which may be incorporated into the electronicsubassembly 12 of the personal care product 10 shown in FIG. 1. Thehousing 16 may be hollow with a first open end 40 and a second open end42. As will be explained in greater detail below, the second open end 42may allow for assembly of various other electrical components within thehousing 16. For example, the housing 16 may define a chamber 44 suchthat the second open end 42 receives the second circuit board assembly(not shown). The first open end 40 may allow for assembly of the firstcircuit board 22.

In certain embodiments, the housing 16 may be first manufactured by aninjection molding process. The housing 16 and the first circuit board 22may then be interconnected as part of a second manufacturing operation.The first circuit board 22 may have a rigid end 46 at one end of theflexible portion 24. The rigid end 46 may be a separate component thatis mounted to the flexible portion to add stiffness and rigidity. Aportion of the first circuit board 22 (e.g., the rigid end 46) may beplaced in an injection mold along with the housing 16 and plastic (e.g.,the plug 26) may be injected around a portion (e.g., the rigid end 46)of the first circuit board 22. The plug 26 and the housing 16 maycomprise the same material such that the two components form a strongbond when molded together.

As shown in FIGS. 2B and 2C, the plastic plug 26 interconnects and sealsthe area between the first circuit board 22 (e.g., rigid end 46) and thehousing 16. Accordingly, the flexible portion 24 may extend outside ofthe housing 16 to allow for connection to other electrical components.

FIG. 2C is a cross section view of the first circuit board subassembly18, taken generally along the line 2C-2C of FIG. 2B. As shown in FIG.2C, a portion of the rigid end 46 may be exposed within the housing 16(e.g., not covered in plastic) to allow for the connection with otherelectronic components. The rigid end 46 may be suspending (e.g.,unsupported) and extend into the chamber 44 of the housing 16. The rigidend 46 may be sufficiently stiff such that it does not deflect onceassembled (e.g., via insert molding) within the housing 16. If the rigidend 46 deflects, it may be difficult to align and/or connect otherelectrical components to the rigid end 46 from within the housing 16.This process may allow not only for sealing one end of the housing 16form water ingress, but may also allow for the precise positioning ofthe rigid end 46 within the housing 16. If the rigid end 46 is notpositioned properly within the housing 16, other electrical componentsmay be impossible to assemble to the first circuit board 22.

However, there are alternative embodiments of how to assembly the firstcircuit board subassembly 18. For example, the first circuit board 22may be placed in a mold and the housing 16 and the plug 26 may be moldedto the first circuit board 22 in a single step. Alternatively, the firstcircuit board 22 may be insert molded with the plug 26 and thenassembled to the housing 16 in a later assembly step. For example, theplug 26 may be inserted into the opening of the housing 16 and sealedusing an O-ring (not shown). The first circuit board 22 may also beinsert molded with the housing 16 in a single step.

Referring to FIG. 3, an assembly view of a portion of the second circuitboard subassembly 20 is illustrated. The second circuit boardsubassembly 20 may include a second circuit board 52 and a chassis 54.The chassis 54 may have a first end 56 and a second end 58. The firstend 56 may include a platform 60 and the second end 58 may include abattery housing 62. The platform 60 may be flat such that the secondcircuit board 52 can be securely mounted to the chassis 54 (i.e., theplatform 60). The battery housing 62 may be generally cylindrical anddefine an opening 64 dimensioned to receive one or more batteries 66.The opening 64 may face in an opposite direction of the platform 60 tomaximize space. In certain embodiments, the battery 66 may include arechargeable battery. One or more electrical connectors 68, 70 may beused to transfer current from the battery 66 to the second circuit board52. The one or more electrical connectors 68, 70 may include powerrails, clips, and/or wires. The battery housing 62 may define a channel72 dimensioned to receive one of the electrical connectors 68. A firstend 74 of the electrical connector 68 may couple to the second circuitboard 52 and a second end 76 of the electrical connector 68 may coupleto a terminal 78 of the battery 66. The other connector 70 may be usedto provide an electrical connection between a second terminal 80 of thebattery 66 and the circuit board 52. A proximal end 82 of the secondcircuit board 52 may have a connector 84 with an opening 86 dimensionedto receive the rigid end 46 of the first circuit board 18 (not shown).

Referring to FIG. 4, an assembly view of the second circuit boardsubassembly 20 into the housing 16 is shown. The chassis 54 may bedimensioned to allow for easy insertion of the second circuit boardsubassembly 20 into the open end 42 of the housing 16. For example, thefirst and second ends 56 and 58 of the chassis 54 may both have a convexsurface 90 and 92 that corresponds to the geometry of the chamber 44(not shown) of the housing 16 to help align the connector 84 of thesecond circuit board 52 with the rigid end 46 (not shown) of the firstcircuit board assembly 18 hidden within the housing 16. The convexsurfaces 90 and 92 may face in opposite directions to allow foradditional room for the mounting of the second circuit board 52 to theplatform 60. In addition, the first end 56 of the chassis 54 may betapered to guide the second circuit board subassembly 20 into the secondopening 42 of the housing 16 and properly align connector 84 within thehousing 16. As will be described in greater detail below, the chassis 54(e.g., the second circuit board 52 and/or the platform 60) may includeone or more guide members 94, 96, such as rails and/or grooves tofacilitate the precise positioning of the chassis 54, and thus theconnector 84 within the housing 16 (not shown).

FIG. 5 is a partial cross section view of the personal care product 10,taken generally along the line 5-5 of FIG. 1. The housing 16 may definethe chamber 44 dimensioned to receive the second circuit boardsubassembly 20. The guide members 94 and 96 may engage a pair ofrespective guide members 98 and 100, such as channels defined by aninner surface of the housing 16. The channels 98 and 100 may providesufficient clearance to allow the chassis 54 to easily slide within thehousing 16 and guide the connector 84 (see FIG. 4) in very closeproximity to the rigid end 46 (see FIG. 2C) of the first circuit board22 (not shown). Accordingly, as previously shown, the guide members 98and 100 facilitate the self-alignment of the second circuit board 52 andthe connector 84 (see FIG. 4) within the chamber 44 of the housing 16.As will be explained in greater detail below, the final position of theconnector 84 within the housing 16 may be facilitated by other featuresof the housing 16.

Referring to FIGS. 6 and 7, the rigid end 46 is illustrated in its finalassembled position within the connector 84. FIG. 6 is a partial crosssection view of the personal care product 10, taken generally along theline 6-6 of FIG. 1. FIG. 7 is a partial cross section view of thepersonal care product 10, taken generally along the line 7-7 of FIG. 1.The second circuit board 52 is positioned within the chamber 44 of thehousing 16 by sliding it in through the opening 42 (e.g., see FIG. 2A)and along the rails 98 and 100 (e.g., see FIG. 5). The housing 16 andthe second circuit board 52 may self-align during assembly such that theconnector 84 is placed in close proximity with that the rigid end 46 ofthe first circuit board 22. As shown in FIG. 6, the housing 16 may havea plurality of ribs 102, 104, 106, 108 that support and guide the finalconnection of the second circuit board 52 (i.e., the connector 84) tothe rigid end 46 of the first circuit board 22. The ribs 102 and 104 mayguide a top surface 112 of the connector 84. The ribs 106 and 108 mayguide a pair of side surfaces 114, 116 of the connector 84 and the rib110 may guide a bottom surface 118 of the connector 84. The ribs 102,104, 106, 108 and 110 facilitate precise alignment of the opening of theconnector 84 with the rigid end 46. Accordingly, a technician can easilyconnect the first circuit board 22 to the second circuit board 52without any visual aids (i.e., seeing the first circuit board 22 and thesecond circuit board 52 during the assembly process). The technician orassembly machine simply inserts the second circuit board into thechamber 44 of the housing 16 through the second opening 42 and theconnector 84 is precisely aligned so the rigid end 46 slides within theopening of the connector 84. No special fixtures or equipment is neededto aid in assembly. The electronic subassembly 20 also eliminates theneed to utilize a more complex and costly clam shell type housing, i.e.in two halves, to connect the electronic components because a techniciandoes not need to see the first circuit board and the second circuitboard in order to properly connect the two components. In addition,insert molding a portion of the first circuit board 22 within thehousing 16, not only facilitates in alignment of the first circuit board22 and the second circuit board 54 during assembly, but also creates afluid seal preventing water ingress into the housing 16. In certainembodiments, the second electronic subassembly 20 may be spaced apartfrom the housing 16 to allow the rigid end 46 of the first circuit board22 to fully seat within the opening 86 of the connector 84, thusproviding a secure and reliable electrical connection. After theconnector 84 and the rigid end 46 are connected, the end cap 95 (seeFIG. 4) may be mounted to the housing 16 to provide a fluid seal.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An electronic subassembly for a personal careproduct comprising: a housing defining a chamber having an open end; afirst circuit board having a rigid end positioned within the chamber anda flexible portion positioned outside the chamber; a second circuitboard positioned within the chamber, the second circuit board having aconnector dimensioned to receive the rigid end of the first circuitboard; and a chassis positioned within the chamber, the chassiscomprising a platform and a battery housing dimensioned to receive abattery, wherein the second circuit board is mounted to the platform. 2.The electronic subassembly of claim 1 wherein at least a portion of thefirst circuit board is fluidly sealed within the housing.
 3. Theelectronic sub assembly of claim 1 further comprising a plurality ofribs supporting the connector that facilitate the alignment of theconnector with the rigid end of the first circuit board.
 4. Theelectronic sub assembly of claim 3 wherein at least one of the ribsdirectly contacts the connector.
 5. The electronic subassembly of claim1 wherein the housing has at least one guide member that slidinglyengages the second circuit board.
 6. The electronic subassembly of claim5 wherein the guide member of the housing comprises a pair of channels.7. The electronic subassembly of claim 5 wherein the second circuitboard comprises a pair of rails that slidingly a pair of correspondingguide members of the housing.
 8. The electronic subassembly of claim 1further comprising an end cap mounted to the end of the housing.
 9. Theelectronic sub assembly of claim 1 wherein the chassis has a taperedfirst end and a second end both positioned within the chamber.
 10. Theelectronic subassembly of claim 1 further comprising a power railconnecting the battery to the second circuit board and the power rail ismounted within a channel on the chassis.
 11. The electronic subassemblyof claim 1 wherein the flexible portion of the first circuit board isconnected to a heating element.
 12. An electronic subassembly for apersonal care product comprising: a housing defining a chamber having anopen end; a first circuit board having a rigid end positioned within thechamber and a flexible portion positioned outside the chamber; a chassispositioned within the housing, the chassis having a first end with aplatform and a second end; a second circuit board mounted to theplatform, the second circuit board having a connector dimensioned toreceive the rigid end of the first circuit board, wherein the housinghas at least one guide member that engages a corresponding guide memberof the chassis.
 13. The electronic subassembly of claim 12 wherein anarea between the first circuit board and the housing is sealedpreventing water ingress.
 14. The electronic subassembly of claim 12wherein the connector is at a proximal end of the second circuit boardand has an opening dimensioned to receive the rigid end of the firstcircuit board.
 15. The electronic subassembly of claim 12 wherein theflexible portion of the first circuit board is connected to a heatingelement.
 16. The electronic subassembly of claim 12 wherein the firstcircuit board is secured within the housing.
 17. The electronicsubassembly of claim 12 wherein the rigid end of a first circuit boardis positioned within the first open end of the housing.
 18. Theelectronic subassembly of claim 12 wherein at least one of the guidemembers comprise a channel configured to receive a corresponding rail.19. A personal care product comprising: a housing defining a chamber; ashaving razor cartridge mounted to the housing; an electrical componentmounted to the cartridge; a first circuit board having a rigid endpositioned within the chamber and a flexible portion positioned outsidethe chamber connected to the electrical component; and a second circuitboard positioned within the chamber, the second circuit board having aconnector dimensioned to receive the rigid end of the first circuitboard.
 20. The personal care product of claim 19 wherein the electricalcomponent is heating element comprising a skin contacting surface.